ECR UTICA BOILERS UB95M-200 Installation, Operation & Maintenance Manual Download Page 3

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iii - rules for safe installation and operation

ii - safety symbols and warninGs

WARNING

This appliance has been equipped for residential instal-

lations. If used for commercial applications, any and all

additional code requirements must be adhered to for in-

stallation. This may require additional controls, including

but not limited to an external water cut off, a manual reset

high temperature limit, and wiring and/or piping modifi-

cations. The manufacturer is not responsible for any field

installation changes made to a boiler installation which are

not described or acknowledged in this manual.

NOTICE

IMPORTANT: Failure to follow these instructions could

cause a malfunction of the boiler and result in death, seri-

ous bodily injury, and/or property damage. For assistance

or additional information, consult a qualified installer,

service agency, or the gas supplier.

Check all applicable state and local building codes and utility

company requirements before installation. This installation

must conform with these requirements in their entirety. In the

absence of these codes, use NFPA installation codes and good

industry practice.
Before servicing the boiler, allow it to cool. Always shut off any

electricity and gas supply connected to the boiler prior to servic-

ing.
Inspect gas line for leaks.

Be certain gas input rate is correct. Over firing may result in

early failure of the boiler components. This may cause danger-

ous operation. Under firing may result in too much air for the

pre-mix burner causing poor or loss of combustion.
Never vent the products of combustion from this boiler to an

enclosed space. Always vent to the outdoors. Never vent to

another room or to inside a building.

Be sure there is adequate outdoor air supply to boiler for com-

plete combustion.
Follow a regular service and maintenance schedule for efficient

and safe operation.
Keep boiler area clean of debris and free of combustible and

flammable materials.
Proper through-the-wall or through-the-roof combustion

venting shall be in accordance with the materials and methods

described in this manual. Installation must comply with local

codes.
This boiler and related hot water heating systems are not do-it-

10.

yourself items. They must be installed and serviced by qualified

professionals. Ratings above are for sea level applications. The

boiler automatically derates input at a rate of 2% for every 1000

feet above an elevation of 2000 feet (see Table 2). The boiler will

also derate relative to the calorific value of the gas being used.

Use the formula specified in “Measure The Natural Gas Input

Rate” in the Control Manual and Troubleshooting Guide (P/N#

240006104) to determine the proper rate due to derated gas. To

ensure proper operation at 5,000 feet of altitude and above, the

minimum RPM setting; parameter 17, must be raised to 3,200.

Instructions on how to change the parameters are included in

the Parameter Guide, part number 240006105.

NOTICE

Indicates information which should be followed to ensure

proper installation and operation.

The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.

DANGER

Indicates an imminently hazardous situation which, if not

avoided, will result in death, serious injury or substantial

property damage.

WARNING

Indicates an imminently hazardous situation which, if not

avoided, may result in death, serious injury or substantial

property damage.

CAUTION

Indicates an imminently hazardous situation which, if not

avoided, may result in injury or property damage.

Summary of Contents for UTICA BOILERS UB95M-200

Page 1: ...mpany Utica BOILERS P O Box 4729 Utica NY 13504 4729 www uticaboilers com Member The Hydronics Institute UB95M 200 Gas Fired Direct Vent Modulating Hot Water Boiler With Outdoor Reset And Built In Low Water Cutoff LWCO INSTALLATION OPERATION MAINTENANCE MANUAL ...

Page 2: ...rbs large amounts of heat from the cast aluminum heat exchanger cooling the flue gases and causing condensation Sealed combustion premix gas burner and low flame temperature means drastically reduced CO and NOx emissions which contribute to a cleaner and healthier environment This appliance unlike normal residential atmospheric and induced draft units takes its combustion air directly from the out...

Page 3: ...o inside a building Be sure there is adequate outdoor air supply to boiler for com 6 plete combustion Follow a regular service and maintenance schedule for efficient 7 and safe operation Keep boiler area clean of debris and free of combustible and 8 flammable materials Proper through the wall or through the roof combustion 9 venting shall be in accordance with the materials and methods described i...

Page 4: ...ping and pickup allowance establishes a reserve for heating the volume of water in the system and offsetting heat losses from the piping The Net I B R Ratings shown are based on a piping and pickup factor of 1 15 in accordance with the I B R Standard as published by the Hydronics Institute The Net I B R Rating of the boiler selected should be greater than or equal to the calculated peak heating lo...

Page 5: ...the provisions of 248 CMR 5 08 2 a 1 through 4 Product approved vent air intake 5 A product approved vent terminal must be used and if applicable a product approved air intake must be used Installation shall be in strict compliance with the manufacturer s instructions Installation instructions 6 A copy of all installation instruc tions for all Product Approved side wall horizontally vented gas fue...

Page 6: ... control replacement etc The boiler must be located where ambient room temperatures 8 minimum possible temperatures where boiler is installed as suming boiler is not in operation and therefore contributes no heat to the space are always at or above 32 F to prevent freez ing of liquid condensate Combustion Air and Vent Pipe Requirements This boiler requires a dedicated direct vent system In a direc...

Page 7: ...0 FT 305 CM MOUNT VENT TERMINATION AT LEAST 36 92 CM FROM INSIDE CORNERS VENT TERMINATION MUST BE INSTALLED WITH A CLEARANCE OF AT LEAST 12 INCHES 31 CM FROM ANY AIR OPENING INTO A BUILDING 12 MIN Through the wall vents for Category II and IV appliances and non categorized condensing appliances shall not terminate over public walk ways or over an area where condensate or vapor could create a nuisa...

Page 8: ...ombustion air must not be taken from inside the structure because that air is frequently contaminated by halogens which include fluorides chlorides phosphates bromides and iodides These elements are found in aerosols detergents bleaches cleaning solvents salts air fresheners paints adhesives and other household products NOTICE Condensate trap is integral to the boiler Wood frame or concrete blocks...

Page 9: ...d cause an unsafe condition When it is practical close all building doors and windows and 3 all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryer and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhaust so they will ...

Page 10: ...on CAUTION Copper supply and return piping must NOT be installed directly into aluminum boiler section castings due to galvanic corrosion between dissimilar metals Iron or steel bushings or pipe nipples should be used between cop per system piping and boiler to make final connection to boiler Also the use of dielectric unions is acceptable The packaged boiler is furnished with iron piping where ne...

Page 11: ...pplied 1 2 PVC tee then transition to pipe and fittings for PVC condensate drain line Condensate drain line to be pitched down to floor drain at a minimum of per foot The diameter schedule 40 PVC condensate drain piping and pipe fittings must conform to ANSI standards and ASTM D1785 Sched ule 40 PVC cement and primer must conform to ASTM D2564 In Canada use CSA or ULC certified schedule 40 PVC dra...

Page 12: ...must be 3 listed to ULC S636 WARNING Do not use cellular core PVC for venting flue gas Combustion air and vent pipe connections on boiler are 2 but 4 must increase to 3 Due to potential for flue gas temperatures above 155 F the first 30 of supplied vent pipe is CPVC while the remaining vent pipe can be PVC Any replacement of the first 30 of vent pipe must be made with CPVC NOTICE NOTE The exhaust ...

Page 13: ...er tight Working from the boiler to the outside cut pipe to required 2 length s Deburr inside and outside of pipe and remove all shavings 3 from pipe Chamfer outside edge of pipe for better distribution of primer 4 and cement Clean and dry all surfaces to be joined 5 Check dry fit of pipe and mark insertion depth on pipe 6 FIELD INSTALL 2 BY 3 TRANSITION IN THE VERTICAL POSITION ONLY 2 REQ D NOT F...

Page 14: ...f run and for the total BTU per hour input of all gas utilization equip ment connected to it See Table 4 for proper size Be sure your gas line complies with local codes and gas company requirements The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of psig 3 5kPa The boiler must b...

Page 15: ... Canada with CSA C22 1 Canadian Electrical Code Part 1 and any local codes L1 L2 Line Voltage Connections Connect 120 VAC power wiring to line voltage terminal strip 1 on boiler control panel Provide and install a fused disconnect or service switch 15 amp 2 recommended as required by code Boiler circulator is shipped loose Wire boiler circulator as 3 shown in wire diagram label on boiler side pane...

Page 16: ...e Voltage Monitor Low Voltage Connections Connect low voltage wiring to low voltage terminal strip as 1 shown in the boiler wiring diagram Route all low voltage wires through opening on the right 2 jacket panel Use shielded cable Thermostat Connect room thermostat or end switch isolated contact 1 only between terminals T1 and T2 Install thermostat on inside wall away from influences of 2 drafts ho...

Page 17: ...articular time NTC Sensors The NTC sensors used with this appliance for measuring sup ply water return water and outside air temperature are specially configured to operate with the modulating boiler control Modulating Blower The modulating blower provides a means of introducing the gas air mixture through the burner and into the combustion chamber where combustion can begin and then out the exhau...

Page 18: ...ng conditions which could damage the boiler The aquastat is mounted in the NPT control well and X bushing on the top of the front boiler section at the hot water outlet The aquastat is tied in with the boiler control and is factory set at 200 F water temperature The high limit setpoint is field adjustable and may be set anywhere between 100 F and 200 F with the maxi mum high limit setpoint not exc...

Page 19: ... valve discharge opening to an open drain tub or sink or other suitable drainage point not subject to freezing in accordance with ASME specifications Failure to provide the pressure relief valve with piping as herein described may cause water damage and or serious bodily injury The boiler manufacturer is not responsible for any water damage or personal injury Check local codes for maximum discharg...

Page 20: ...r manufacturer s stated acceptable range pH 7 0 to 8 0 are indications that the system should be cleaned or treated Measure total capacity of the system including the piping tanks 1 boiler collector plates etc The most accurate method of mea suring fluid capacity is to fill the system and then completely drain it volumetrically measuring the fluid drained Thoroughly flush the system with clean wat...

Page 21: ...eze manufacturer for potential hazards and first aid procedures for exposure or ingestion Antifreeze Testing Services Each of the recommended antifreeze manufacturers have developed a sampling program available to the homeowner and contractor Contact the antifreeze manufacturer regarding their sampling plan procedure Consult the antifreeze manufacturer for details on sample requirements and recomm...

Page 22: ... vent D Fill the tank to the proper level and close the tank vent Remove the handle from the expansion tank service valve so the homeowner doesn t accidentally close it Open all service valves Any air remaining trapped in the E return lines between the service valves and the boiler will be pushed towards the expansion tank when the boiler is placed in operation Inspect piping system Repair any lea...

Page 23: ...mation of aluminum oxide This oxide formation is normal is generally uniform throughout the boiler sections and represents a negligible mass of aluminum that is con sumed by oxidation during the life of the boiler If left unchecked this buildup may eventually cause blockage of the flue gas passages in the boiler sections reducing efficiency and ultimately shutting down the boiler due to lack of co...

Page 24: ...Manual and Operating Instructions P N 240006104 If heating system is to remain out of service during freezing 2 weather and does not contain antifreeze drain system com pletely If boiler will be exposed to freezing temperatures drain condensate lines Annual examination and cleaning of boiler components WARNING The following service procedures must be performed by a qualified service agency using t...

Page 25: ...gas line to gas valve pressure switch hose to gas valve and air inlet assembly igniter wires and gas valve wires Visually inspect the condensate trap Any foreign material vis 4 ible in the condensate lines needs to be cleaned out as described below Inspect for sediment or blockage Flush out with water or vacuum Follow the instructions in Section VII Filling The Con densate Trap With Water Inspect ...

Page 26: ...26 ...

Page 27: ...IS REPLACED IT MUST BE REPLACED WITH LIKE WIRE SIZE AND TYPE OF INSULATION OR EQUIVALENT SI AUCUN DES FILS ORIGINAUX FOURNIS AVEC LA CHAUDÈRE EST REMPLACÉ IL DOIT ÊTRE REMPLACÉ OAR UN AUTRE FIL DE MÊME GROSSEUR ET DU MÊME TYPE D ISOLATION OU L ÉQUIVALENT DISPLAY DHW C1 DHW C2 L N PE DHW PUMP 117 VAC FIELD INSTALLED CH PUMP 117 VAC FIELD INSTALLED CH C2 PE N CH C1 L COMBUSTION FAN 117 VAC N PWM FSP...

Page 28: ...1 DHW T1 CH T2 CH T1 OUTDOOR AIR SENSOR BOILER CONTROL PANEL DHW CIRC L1 120 VAC L2 CH CIRC Note The CH DHW Circulator connections on the boiler will only support a pump with a 1 amp rating or less Boiler Control Wiring Diagram Single Zone System With Domestic Hot Water Priority 28 ...

Page 29: ...er CH C1 L1 T STAT L2 CH C2 DHW C2 DHW C1 DHW T2 A2 A1 DHW T1 CH T2 CH T1 OUTDOOR AIR SENSOR aquastat or thermostat Boiler Control Panel DHW CIRC L1 HOT L2 N 120V AC NO L2 VAC 120 4 4 NC AR822 II TORQUE TERMINAL 6 TO 7 INCH LBS ELECTRONIC FUSE CIRCUIT ON AR822 TT R T TT NO 24V W C T 5 SCREWS NC 6 6 CH CIRC XVI piping and wiring appendix Piping Diagram 1 Single Zone System With Domestic Hot Water P...

Page 30: ...G ZONE CIRCULATOR SEE FIGURE 5 ZONE 4 CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE EXPANSION TANK AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE NOTE NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS XVI piping and wiring appendix Piping Diagram 2 Multizone Piping With Zone Valves And Domestic Hot Water Priority With Zone Valve 30 ...

Page 31: ...MPER ZONE VALVE PUMP PRIORITY ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 SWITCH LEGEND OFF ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM BOILER X X TRANSFORMER 24VAC 40 VA L LINE IN N Black White 24VAC N L Yellow Yellow AZ 4CP Boiler Control Panel DHW C1...

Page 32: ...DHW CIRCULATOR CH CIRCULATOR CIRCULATOR FLOW CONTROL VALVE SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB EXPANSION TANK NOTE NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS Piping Diagram 3 Multizone System With Zone Valves And Domestic Hot Water Priority With Circulator 32 ...

Page 33: ... ONLY 2 1 3 4 JUMPER ZONE VALVE PUMP PRIORITY ON ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 SWITCH LEGEND OFF ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM BOILER X X TRANSFORMER 24VAC 40 VA L LINE IN N Black White 24VAC N L Yellow Yellow AZ 4CP Boiler C...

Page 34: ...CULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE EXPANSION TANK XVI piping and wiring appendix NOTE NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS Piping Diagram 4 Multizone System With Circulators And Domestic Hot Water Priority 34 ...

Page 35: ...T T 3 R ZONE 4 W T 4 R T DHW CIRC L2 CH C2 DHW C2 DHW C1 DHW T2 A2 A1 DHW T1 CH T2 CH T1 OUTDOOR AIR SENSOR aquastat or thermostat Boiler Control Panel 115 V COIL ISOLATION RELAY NORMALY OPEN NOTE IN PLACE OF 115 VOLT ISOLATION RELAY OPTIONAL CONTROL ARGO AR822II TERMINAL 5 6 N O TO DHW T1 DHW T2 L1 L2 TO ARM L N ON PRIORITY ZONE ELECTRONIC FUSE VAC CIRCUIT ON 120 L2 NO 4 NC 4 AR822 TT SCREWS TORQ...

Page 36: ...D FLOW IN SECONDARY ZONE 4 DHW PUMP CIRCULATOR PUMP SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE EXPANSION TANK WATER INLET SEE NOTE NOTE RECOMMENDED FOR ANTIFREEZE APPLICATIONS Piping Diagram 5 Primary Secondary Piping With Circulators And Domestic Hot Water Piping Diagram 5 36 ...

Page 37: ...IRC 3 ZONE 4 ZONE 4 ZONE 3 ZONE 2 N 2 L N 3 L ZONE 3 ZONE 2 120 VAC 4 N L N PRIORITY ON INDIRECT HOT WATER HEATER AQUASTAT OR THERMOSTAT W T STAT DATA PORT X X ZR ZC W T PRIORITY T 1 ZONE T R ZONE 4 THERMOSTATS ZONE 3 T ZONE 2 2 W T R 3 T TW R TO EXTRA ZONE MODULE T 4 R 1VA 24 VAC COMMON T STAT T STAT 15 VA 2 7K SILKSCREEN 1 2K L1 L2 TO ARM L N ON PRIORITY ZONE ELECTRONIC FUSE VAC CIRCUIT ON 120 L...

Page 38: ... 4 USE FULL PORT ZONE VALVE FOR OPTIMUM TANK PERFORMANCE CONSIDER USING ZONE CIRCULATOR SEE FIGURE 13 CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE EXPANSION TANK NOTE RECOMMENDED FOR ANTIFREEZE APPLICATIONS SEE NOTE Piping Diagram 6 Primary Secondary Multizone System Piping With Zone Valves And Domestic Hot Water With ...

Page 39: ...VAC CIRCUIT ON 120 L2 N O 4 N C 4 AR822 TT TT T T R W 24V C 5 6 6 RELAY TRANSFORMER N O N C 24VAC 15 VA 24VAC L1 3 FACTORY INSTALLED JUMPER ZONE VALVE PUMP PRIORITY ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM ...

Page 40: ...USE FULL PORT ZONE VALVE DHW CIRCULATOR PUMP CH CIRCULATOR PUMP WATER INLET CIRCULATOR PUMP SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE EXPANSION TANK NOTE RECOMMENDED FOR ANTIFREEZE APPLICATIONS SEE NOTE Piping Diagram 7 Primary Secondary Piping With Zone Valves And Domestic Hot Water With Circulator 40 ...

Page 41: ... ON 120 L2 N O 4 N C 4 AR822 II T T R W 24V C 5 6 6 RELAY TRANSFORMER N O N C 24VAC 15 VA 24VAC L1 3 FACTORY INSTALLED JUMPER ZONE VALVE PUMP PRIORITY ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM BOILER X X TRA...

Page 42: ...E 3 WAY MIXING VALVE AIR SEPARATOR HOSE BIB EXPANSION TANK BOILER ALTERNATE CIRCULATOR LOCATION TO SYSTEM FROM SYSTEM V2 V1 CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE EXPANSION TANK WATER INLET SYSTEM CIRCULATOR Piping Diagram 8 Bypass Piping Automatic Mixing Valve Piping Diagram 9 Bypass Piping Fixed Low Temp Only 42 ...

Page 43: ...OL VALVE 4 WAY MIXING VALVE EXPANSION TANK 12 MAX 12 MAX CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR 3 WAY MIXING VALVE TO SYSTEM FROM SYSTEM ALTERNATE CIRCULATOR LOCATION ALTERNATE CIRCULATOR LOCATION BOILER 1 BOILER 2 EXPANSION TANK WATER INLET Piping Diagram 10 Bypass Piping 4 Way Valve Option With Circulator On Supply Piping Diagram 11 Multiple Boiler ...

Page 44: ...E TO BOILER T T TO BOILER T T TERMINALS 1 2 TRANSFORMER 24VAC 40 VA Black White Yellow Yellow DHW C1 DHW C2 CH C2 CH C1 A2 DWH T1 DHW T2 A1 BOILER CONTROL PANEL CH T1 CH T2 L1 L2 120 V WHITE BLACK BOILER 1 CIRC DHW C1 DHW C2 CH C2 CH C1 A2 DWH T1 DHW T2 A1 BOILER CONTROL PANEL CH T1 CH T2 L1 L2 BOILER 2 CIRC AMB 8 BOILER 1 BOILER 2 IF USING REQ ACK CONNECT HERE TT THERMOSTAT DRY CONTACT IF USING E...

Page 45: ...45 ...

Page 46: ...46 ...

Page 47: ...NOTES ...

Page 48: ...Date Service Performed Company Name Tech Initials Company Address Phone ...

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